Electric vehicle battery tray bracket

ABSTRACT

An electric vehicle includes an electric-vehicle battery tray including a frame member elongated along a vehicle-longitudinal axis. The electric vehicle includes a rocker rail elongated along the vehicle-longitudinal axis. The electric vehicle includes a subframe. The electric vehicle includes a bracket connecting the battery tray, the rocker rail, and the subframe.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation of and claims priority to andall the benefits of U.S. patent application Ser. No. 17/225,271 filed onApr. 8, 2021, which is herein incorporated by reference in its entirety.

BACKGROUND

An electric vehicle includes a battery that powers the vehicle,including propulsion of the vehicle. For example, wheels of the vehicleare powered by one or more electric motors that are powered by thebattery. The battery is relatively large and heavy and, accordingly, thebattery is typically packaged below the passenger compartment of thevehicle. The battery may be subject to being shorted during certainvehicle impacts if loads are applied to the battery and/or if thecooling system used to cool the battery leaks coolant on the battery.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an electric vehicle having anelectric-vehicle battery tray connected to both a rocker rail and asubframe with a bracket.

FIG. 2 is a bottom view of a portion the electric vehicle having abracket.

FIG. 3 is a bottom perspective view of a portion the electric vehiclehaving the bracket of FIG. 2 .

FIG. 4 is a bottom view of a portion the electric vehicle having theelectric-vehicle battery tray connected to the rocker rail and thesubframe with the bracket of FIG. 1 .

FIG. 5 is a side view of a portion the electric vehicle having thebracket of FIG. 1 .

FIG. 6 is a bottom perspective view of a portion the electric vehiclehaving the bracket of FIG. 1 .

DETAILED DESCRIPTION

An electric vehicle includes an electric-vehicle battery tray includinga frame member elongated along a vehicle-longitudinal axis. The electricvehicle includes a rocker rail elongated along the vehicle-longitudinalaxis. The electric vehicle includes a subframe. The electric vehicleincludes a bracket connecting the battery tray, the rocker rail, and thesubframe.

The electric vehicle may include an electric-vehicle battery supportedby the battery tray.

The electric vehicle may include a wheel supported by the subframevehicle-forward of the bracket.

The wheel may define a movement path during a vehicle impact, themovement path extends reward from the wheel, and the bracket includes afront surface that extends at an obtuse angle relative to the movementpath.

The movement path may be defined by movement of the wheel during a smalloverlap rigid barrier crash test.

The bracket may be directly in front of the frame member along thevehicle-longitudinal axis.

The battery tray may include a second frame member elongated along avehicle-lateral axis and fixed to the bracket.

The electric vehicle may include a second rocker rail spaced from therocker rail with the battery tray disposed between the rocker rail andthe second rocker rail, and a second bracket fixed to the battery tray,the second rocker rail, and the subframe.

The bracket may be unitary.

The bracket may be designed to distribute force from the subframe toboth the rocker rail and the battery tray during a vehicle front impact.

The bracket may include a plurality of ribs defining openingstherebetween.

The openings each have an open top and an open bottom.

The bracket may be fixed to the subframe at first attachment point and asecond attachment point, to the battery tray at a third attachment pointand a fourth attachment point, and to the rocker rail at a fifthattachment point and a sixth attachment point.

The bracket may include a first rib extending from the first attachmentpoint to the third attachment point and a second rib extending from thesecond attachment point to the fourth attachment point.

The bracket may include a third rib extending from the first attachmentpoint to the fifth attachment point and a fourth rib extending from thesecond attachment point to the sixth attachment point.

The bracket may include a fifth rib extending from the second rib to thethird rib.

The bracket may include a first sub-bracket and a second sub-bracket,both fixed to the battery tray, the rocker rail, and the subframe.

The first sub-bracket may be fixed to the second sub-bracket about aperimeter of the bracket.

The bracket may include a flange extending downward away from thebattery tray.

The electric vehicle may include a control arm and a control arm bracketsupported by the subframe, the control arm bracket having a secondflange extending downward away from the battery tray.

With reference to the Figures, wherein like numerals indicate like partsthroughout the several views, an electric vehicle 20 includes anelectric-vehicle battery tray 22 that has a frame member 24 elongatedalong a vehicle-longitudinal axis A1. The electric vehicle 20 includes arocker rail 26 elongated along the vehicle-longitudinal axis A1. Theelectric vehicle 20 includes a subframe 28. The electric vehicle 20includes a bracket 30, 30′ connecting the battery tray 22, the rockerrail 26, and the subframe 28.

The bracket 30, 30′ distributes force applied to the subframe 28, e.g.,during an offset front impact to the vehicle 20, to the rocker rail 26and the frame member 24. Such force distribution may reduce deformationof the battery tray 22.

In the following description, relative orientations and directions (byway of example, top 40, bottom 42, front, rear, forward, rearward,upward, downward, outboard, inboard, inward, outward, lateral, left,right, etc.) are from the perspective of an occupant seated in a seat,facing a dashboard of the electric vehicle 20.

With reference to FIGS. 1-6 , the electric vehicle 20 may be anysuitable type of automobile that generates propulsion from electricpower, e.g., a battery-electric vehicle (BEV), a hybrid-electric vehicle(HEV), a plug-in hybrid electric vehicle (PHEV), a passenger orcommercial automobile such as a sedan, a coupe, a truck, a sport utilityvehicle, a crossover vehicle, a van, a minivan, a taxi, a bus, etc. Theelectric vehicle 20 may be, for example, an autonomous vehicle. In otherwords, the electric vehicle 20 may be autonomously operated such thatthe electric vehicle 20 may be driven without constant attention from adriver, i.e., the electric vehicle 20 may be self-driving without humaninput.

The electric vehicle 20 defines the longitudinal axis A1, e.g.,extending between a front 32 and a rear 34 of the electric vehicle 20.The electric vehicle 20 defines a lateral axis A2, e.g., extendingbetween a left side 36 and a right side 38 of the electric vehicle 20.The electric vehicle 20 defines a vertical axis A3, e.g., extendingbetween a top 40 and a bottom 42 of the electric vehicle 20. Thelongitudinal axis A1, the lateral axis A2, and the vertical axis A3 areperpendicular to each other.

The electric vehicle 20 includes a frame 44 that supports vehiclecomponents and provides rigidity to the electric vehicle 20. Theelectric vehicle 20 may be of a unibody construction. In the unibodyconstruction, components of the frame 44 and a body of the electricvehicle 20, e.g., rocker rails 26, a floor, a pillars, etc., serve asthe frame 44. The frame 44 may be formed of any suitable material, forexample, steel, aluminum, and/or fiber-reinforced plastic, etc.

The electric vehicle 20 may include wheel wells 46 that house wheels 48.The wheel wells 46 may have an arch shape that is open on an outboardside and enclosed on an inboard side. Two wheel wells 46 may be on eachof the right side 38 and the left side 36 of the vehicle 20, e.g., withone at the front 32 and one at the rear 34 of each side 36, 38.

The rocker rails 26 provide rigidity at the right side 38 and the leftside 36 of the electric vehicle 20 and support other vehicle components,such as doors in closed positions. The rocker rails 26 may be the lowestportion of the sides 36, 38 of the vehicle 20. The rocker rails 26 areelongated along the longitudinal axis A1. The rocker rails 26 are spacedfrom each other along the lateral axis A2. One rocker rail 26 may extendbetween the wheel wells 46 of each side 36, 38 of the vehicle 20, e.g.,along the vehicle-longitudinal axis A1.

An electric-vehicle battery 50 powers propulsion of the electric vehicle20, e.g., powers a drivetrain motor. The electric-vehicle battery 50 maybe of any suitable type for vehicular electrification, for example,lithium-ion batteries, nickel-metal hydride batteries, lead-acidbatteries, ultracapacitors, etc. The electric-vehicle battery 50 mayinclude at least one battery module. Each battery module may include oneor more battery cells. The electric-vehicle battery 50 may include anysuitable hardware, e.g., wiring, connectors, circuits, etc., connectingthe battery modules to each other and to electrified components of theelectric vehicle 20.

The battery tray 22 supports the electric-vehicle battery 50 on theframe 44. For example, the battery tray 22 may include a compartmentthat receives the battery modules. The battery tray 22 may be disposedbetween the rocker rails 26 along the lateral axis A2. The battery tray22 may be fixed to the frame 44, e.g., to the rocker rails 26, thefloor, etc.

The battery tray 22 includes first frame members 24 elongated along thelongitudinal axis A1. The first frame members 24 may be spaced from eachother along the lateral axis A2, e.g., with the compartmenttherebetween. The battery tray 22 may include second frame members 52elongated along the lateral axis A2. The second frame members 52 may bespaced from each other along the longitudinal axis A1, e.g., with thecompartment therebetween. The battery tray 22 may include panels that,e.g., a bottom panel 54, a top panel (not shown in the figures thatenclose the electric-vehicle battery 50. The panels may preventintrusion of precipitation and dirt to the electric-vehicle battery 50.The top panel may separate the electric-vehicle battery 50 fromcomponents of the electric vehicle 20 above the battery tray 22, e.g., apassenger compartment. The first frame members 24, the second framemembers 52, and the panels may be fixed to each other, the rocker rails26, the floor, and/or any other suitable structure of the frame 44.

The subframe 28 supports vehicle components, e.g., steering components,suspension components, etc. The subframe 28 may include beams, panels,etc. The subframe 28 may be metal or any material of sufficient strengthand rigidity. The subframe 28 is a discrete, separate structure from theframe 44. The subframe 28 is connected to the frame 44. For example, thesubframe 28 may be welded to the frame 44, bolted to the frame 44, fixedto the frame 44 fastener, etc. One or more dampeners, e.g., rubberbushings, springs, etc., may be disposed between the frame 44 and thesubframe 28. The subframe 28 is forward of the battery tray 22. Forexample, the subframe 28 may be at the front 32 of the vehicle 20.

The vehicle 20 may include control arms 56 that support the wheels 48 atthe front 32 of the vehicle 20. The control arms 56 provide a hingedsuspension link between the wheels 48 at the front 32 of the vehicle 20and, for example, the subframe 28. The control arm 56 may be supportedby the subframe 28, e.g., at the right side 38 and the left side 36.

As shown in FIG. 2-6 , a control arm bracket 58 may be fixed to thesubframe 28 at a pivot point where the control arm 56 connects to thesubframe 28. The control arm bracket 58 includes a control arm flange 60that deflects debris, e.g., gravel from a road surface, away from thebattery tray 22. The control arm flange 60 extends downward away fromthe battery tray 22, e.g., along the vertical axis A3 to a distal edge62. The distal edge 62 of the control arm flange 60 is lower than thebattery tray 22. The control arm flange 60 may be elongated along thelateral axis A2, i.e., longer along the lateral axis A2 than along thelongitudinal axis A1 and the vertical axis A3.

Each of the wheels 48 at the front 32 of the vehicle 20 defines amovement path P, shown in FIGS. 2 and 4 . The movement path P is apredicted trajectory of the wheel 48 during a vehicle impact to thefront 32 of the vehicle 20. Deformation of, and movement interferencefrom, certain vehicle components, e.g., the control arms 56, suspensioncomponents, and/or steering components, control movement of the wheel 48during the vehicle impact shape the movement path P. The movement path Pextends reward from the wheel 48, e.g., toward the rocker rail 26 andthe battery tray 22 along the longitudinal axis A1. The movement path Pmay extend diagonally inward along the lateral axis A2, i.e., toward acenter of the vehicle 20 along the lateral axis A2. The movement path Pmay be defined by movement of the wheel 48 during a small overlap rigidbarrier (SORB) crash test. For example, the vehicle 20 may be subject toa SORB crash test in conformity with Insurance Institute for HighwaySafety (IIHS) standards, and movement of the wheel 48 during such testmay provide the movement path P.

The bracket 30, 30′ is designed to distribute force from the subframe 28to both the rocker rail 26 and the battery tray 22 during a vehicle 20front 32 impact. For example, the vehicle 20 front 32 impact may applyforce to the subframe 28. The brackets 30, 30′ receive such force anddirect the force to the rocker rails 26 and the battery tray 22, e.g.,to the first frame members 24. The distribution of force from thesubframe 28 to the rocker rails 26 and first frame members 24 reducesdeformation of the compartment housing the electric-vehicle battery 50.

The brackets 30, 30′ connect the battery tray 22, the subframe 28, andthe rocker rails 26. One bracket 30, 30′ connects, e.g., is fixed to,the battery tray 22, the subframe 28, and the rocker rail 26 at theright side 38 of the vehicle 20. Another bracket 30, 30′ connects, e.g.,is fixed to, the battery tray 22, the subframe 28, and the rocker rail26 at the left side 36 of the vehicle 20. The brackets 30, 30′ may bedirectly in front of the first frame members 24 along the longitudinalaxis A1. In other words, the bracket 30, 30′ may be forward of the firstframe members 24 and at common positions along the lateral axis A2 asthe first frame members 24. One bracket 30, 30′ may be directly in front32 of the first frame member 24 at the right side 38 and another bracket30, 30′ may be directly in front 32 of the first frame member 24 at theleft side 36.

The bracket 30, 30′ may be designed to inhibit the wheels 48 at thefront 32 of the vehicle 20 from embedding into the wheel wells 46, e.g.,during a SORB crash test. The bracket 30, 30′ may include a frontsurface 64 designed to urge the wheel 48 traveling long the movementpath P outward from the wheel well 46. The front surface 64 extends atan obtuse angle α relative to the movement path P, as shown in FIGS. 2and 4 . The obtuse angle α is measured outboard of the movement path Pand in a plane extending along the longitudinal axis A1 and the lateralaxis A2. In other words, the front surface 64 may define a normal vectorthat is transverse to, and extends outboard of, the movement path P.

The bracket 30, 30′ may be unitary, i.e., a single component that is notdisassemble into smaller separate components with destructive processes.For example, the bracket 30 may be monolithic, i.e., a single, uniformpiece of material with no seams, joints, fasteners, or adhesives and/orformed together simultaneously as a single continuous unit, e.g., bymachining from a common blank, molding, forging, casting, 3-D printing,etc. As another example, the bracket 30′ may include component that arepermanently fused together, e.g., via welding or the like. Non-unitarycomponents, in contrast, are formed separately and subsequentlyassembled, e.g., by threaded engagement, fastener, etc. Non-unitarycomponents may be disassembly without destructive processes, e.g., viaunthreading a fastener.

The wheels 48 at the front 32 of the vehicle 20 are supported by thesubframe 28 forward of the respective brackets 30, 30′ at the right side38 and the left side 36, e.g., via the control arms 56 and/or otherstructure. During an impact to the front 32 of the vehicle 20, e.g., aSORB crash test, crash forces may urge the wheel 48 at the right side 38or the left side 36 along the movement path P toward the bracket 30,30′. Normal forces between the front surface 64 of the bracket 30, 30′and the wheel 48 may urge the wheel 48 outboard of the vehicle 20 andaway from the wheel well 46, e.g., inhibiting the wheel 48 at the front32 of the vehicle 20 from embedding into the wheel well 46.

With reference to FIGS. 3 , the brackets 30 may be fixed to the subframe28 at first attachment point 66 and a second attachment point 68, to thebattery tray 22 at a third attachment point 70 and a fourth attachmentpoint 72, and to the respective rocker rail 26 at a fifth attachmentpoint 74 and a sixth attachment point 76. For example, a bolt or othersuitable fastener may fix the brackets 30, 30′ to the subframe 28,rocker rails 26, and battery tray 22 at each of the attachment points66, 68, 70, 72, 74, 76.

Each of the brackets 30 may include a first rib 78 extending from thefirst attachment point 66 to the third attachment point 70 and a secondrib 80 extending from the second attachment point 68 to the fourthattachment point 72. The first rib 78 and the second rib 80 distributeforce from the subframe 28 to the battery tray 22.

Each of the brackets 30 may include a third rib 82 extending from thefirst attachment point 66 to the fifth attachment point 74 and a fourthrib 84 extending from the second attachment point 68 to the sixthattachment point 76. The third rib 82 and the fourth rib 84 distributeforce from the subframe 28 to the respective rocker rail 26.

Each bracket 30 may include a fifth rib 86 extending from the second rib80 to the third rib 82. The fifth rib 86 reinforces, and distributesforce between, the second rib 80 and the third rib 82.

Each bracket 30 may include a plurality of cross ribs 88 extendingbetween the first rib 78 and the second rib 80 and between the third rib82 and the fourth rib 84. The cross ribs 88 reinforce, and distributeforce between, the first rib 78 and the second rib 80, and the third rib82 and the fourth rib 84.

The ribs 78, 80, 82, 84, 86, 88 define openings 90 therebetween. Theopenings 90 may each have an open top and an open bottom. In otherwords, the openings 90 may extend completely through the bracket 30, 30′along the vertical axis A3.

The bracket 30 may be monolithic, e.g., the ribs 78, 80, 82, 84, 86, 88may be a single, uniform piece of material with no seams, joints,fasteners, or adhesives and/or formed together simultaneously as asingle continuous unit.

With reference to FIG. 6 , each of the brackets 30′ may include a firstsub-bracket 92 and a second sub-bracket 94, both fixed to the batterytray 22, the respective rocker rail 26, and the subframe 28. Forexample, the first sub-bracket 92 of the bracket 30′ on the right side38 is fixed to the battery tray 22, the rocker rail 26 on the right side38, and the subframe 28, and the second sub-bracket 94 of the bracket30′ on the right side 38 is fixed to the battery tray 22, the rockerrail 26 on the right side 38, and the subframe 28. The first sub-bracket92 and the second sub-bracket 94 of each bracket 30′ may be fixed to thebattery tray 22, the respective rocker rail 26, and the subframe 28 withcommon fasteners. For example, a bolt may extend though both the firstsub-bracket 92 and the second sub-bracket 94 to fix the bracket 30′ tothe subframe 28, or other component. The first sub-bracket 92 and thesecond sub-bracket 94 may be stacked on top 40 of each other, e.g., withthe second sub-bracket 94 above the first sub-bracket 92 and between thesubframe 28 and the first sub-bracket 92. The first sub-bracket 92 maybe fixed to the second sub-bracket 94 about a perimeter of the bracket30′. For example, a weld 96 may fix the first sub-bracket 92 to thesecond sub-bracket 94, surrounding an outer surface of the firstsub-bracket 92 and the second sub-bracket 94. The weld 96 may extendalong the longitudinal axis A1 and the lateral axis A2.

With reference to FIGS. 5 and 6 , the brackets 30′ may include a flange98 that deflects debris, e.g., gravel from a road surface, away from thebattery tray 22. For example, the first sub-bracket 92 may include theflange 98 The flange 98 extends downward away from the battery tray 22,e.g., along the vertical axis A3 to a distal edge 100. The distal edge100 of the flange 98 is lower than the battery tray 22. The flange 98may be elongated along the lateral axis A2.

The adjectives “first,” “second,” etc., are used throughout thisdocument as identifiers and are not intended to signify importance ororder.

The disclosure has been described in an illustrative manner, and it isto be understood that the terminology which has been used is intended tobe in the nature of words of description rather than of limitation. Manymodifications and variations of the present disclosure are possible inlight of the above teachings, and the disclosure may be practicedotherwise than as specifically described.

What is claimed is:
 1. A vehicle, comprising: an electric-vehiclebattery tray; a rocker rail elongated along a vehicle-longitudinal axis;a subframe; and a first sub-bracket and a second sub-bracket fixed tothe first sub-bracket, the first sub-bracket and the second sub-bracketboth being fixed to the battery tray, the rocker rail, and the subframe.2. The vehicle of claim 1, wherein the second sub-bracket is stacked onthe first sub-bracket above the first sub-bracket.
 3. The vehicle ofclaim 2, wherein the second sub-bracket is between the subframe and thefirst sub-bracket.
 4. The vehicle of claim 3, wherein the firstsub-bracket is fixed to the second sub-bracket about an outer surface ofthe first sub-bracket and the second sub-bracket.
 4. The vehicle ofclaim 3, further comprising a weld between the first sub-bracket and thesecond sub-bracket.
 5. The vehicle of claim 4, wherein the weld extendsalong the vehicle-longitudinal axis and a vehicle-lateral axis.
 6. Thevehicle of claim 1, further comprising a weld between the firstsub-bracket and the second sub-bracket.
 7. The vehicle of claim 1,wherein the second sub-bracket is between the subframe and the firstsub-bracket.
 8. The vehicle of claim 1, wherein the first sub-bracket isfixed to the second sub-bracket about an outer surface of the firstsub-bracket and the second sub-bracket.
 9. The vehicle of claim 1,wherein the first sub-bracket and the second sub-bracket are both fixedto the subframe with a fastener that extends through both the firstsub-bracket and the second sub-bracket.
 10. The vehicle of claim 1,wherein the first sub-bracket includes a flange extending downward awayfrom the battery tray.
 11. The vehicle of claim 10, wherein the flangeextends downward away from the battery tray to a distal edge, the distaledge being lower than the battery tray.
 12. The vehicle of claim 11,wherein the flange is elongated along a vehicle-lateral axis.
 13. Thevehicle of claim 10, further comprising a control arm and a control armbracket supported by the subframe, the control arm bracket having asecond flange extending downward away from the battery tray.
 14. Thevehicle of claim 13, wherein the flange and the second flange areelongated along a vehicle-lateral axis.
 15. The vehicle of claim 1,further comprising an electric-vehicle battery supported by the batterytray.
 16. The vehicle of claim 1, further comprising a wheel supportedby the subframe vehicle-forward of the bracket.
 17. A vehicle,comprising: an electric-vehicle battery tray; a rocker rail elongatedalong a vehicle-longitudinal axis; a subframe; and a bracket fixed tothe battery tray, the rocker rail, and the subframe; the bracketincluding a flange extending downward to a distal end lower than thebattery tray.
 18. The vehicle of claim 17, wherein the bracket includesa first sub-bracket and a second sub-bracket stacked on and fixed to thefirst sub-bracket, the first sub-bracket including flange.
 19. Thevehicle of claim 17, further comprising: an electric-vehicle batterysupported by the battery tray; and a wheel supported by the subframevehicle-forward of the bracket.